Alamo INTERSTATER Operator'S Manual Download Page 158

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MAINTENANCE

INTERSTATER 03/09

Maintenance Section 5-4

MAINTENANCE

ADJUSTING TENSION OF DRIVEBELTS

Remove Pump Cover.

Loosen Pump Mount Plate bolt item 1 and 2.

Mnt-FL-0010

Loosen Belt Tension Bracket bolt item 3. Mnt-
FL-0010

Move pump unit outwards to increase tension
on the belt. Belts should have no more than 1/4
inch play at midpoint between drive pulley and
pump pulley. Tighten mounting bolts.

Replace Pump Cover.

CHANGING HYDRAULIC SYSTEM FILTER

A large capacity filter is located on top of the hydraulic oil reservoir.

Mnt-FL-0009

The filter will trap particles

which are .001 inch or larger. The filter needs to be changed after the first 10 hours of operation and every 200
hours or 12 months thereafter.

1. Clean the filter cover to prevent dirt from entering tank.

2. Loosen the four bolts on the filter cover.

Mnt-FL-0004

Remove one bolt from the filter to aid in removing the

filter cover.

Mnt-FL-0005

3. Push the filter cover down and slowly twist the filter cover off.

Mnt-FL-0006

4. Remove filter spring.

Mnt-FL-0007

Summary of Contents for INTERSTATER

Page 1: ...30 372 3551 Email parts alamo industrial com FLAIL MOWER This Operator s Manual is an integral part of the safe operation of this machine and must be maintained with the unit at all times READ UNDERSTAND and FOLLOW the Safety and Operation Instructions contained in this manual before operating the equipment C01 Cover INTERSTATER ...

Page 2: ...safety equipment properly attached to minimize the chance of acci dents BEFORE YOU START Read the safety messages on the implement and shown in your manual Observe the rules of safety and common sense WARRANTY INFORMATION Read and understand the complete Warranty Statement found in this Manual Fill out the Warranty Registration Form in full and return it to within 30 Days Make certain the Serial N...

Page 3: ...OL VALVE 3 11 HYDRAULICS 3 12 CONTROL CABLE CONNECTION TO CONTROL STICK ASSEMBLIES 3 19 INITIAL START UP PROCEDURE 3 20 FINAL CHECK 3 21 INSTALLATION OF REAR MOWER 3 22 OPERATION SECTION 4 1 Standard Equipment and Specifications 4 3 OPERATOR REQUIREMENTS 4 4 TRACTOR REQUIREMENTS 4 5 ROPS and Seat Belt 4 5 Tractor Safety Devices 4 5 Tractor Horsepower 4 5 GETTING ON AND OFF THE TRACTOR 4 6 Boarding...

Page 4: ...ING GUIDE 4 42 MAINTENANCE SECTION 5 1 DAILY CHECKS 5 2 ADJUSTING TENSION OF DRIVEBELTS 5 4 CHANGING HYDRAULIC SYSTEM FILTER 5 4 CUTTER UNIT 5 6 GENERAL MAINTENANCE 5 6 REPLACING CUTTER UNIT DRIVEBELTS 5 7 ADJUSTING CUTTING HEIGHT 5 7 ROLLER BEARING REPLACEMENT 5 8 CUTTERSHAFT BEARING REPLACEMENT 5 9 Outboard Bearing 5 9 Inboard Drive Bearing 5 10 CUTTERSHAFT REPLACEMENT 5 10 CHANGING TO FORWARD O...

Page 5: ...SEASONAL CLUTCH MAINTENANCE 5 27 Proper Torque for Fasteners 5 28 ...

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Page 7: ...own this video and presented you a DVD Video when you purchased your mower If you or any mower operator have not seen this video Watch the Video Read this Operator s Manual and Complete the Video Guidebook before operating your new mower If you do not understand any of the instructions included in the video or operator s manual or if you have any questions concerning safety of operation contact yo...

Page 8: ...EMA Mower Operator Safety Video Mower Operator s Manual AEM Mower Operator s Safety Manual Requester Name Phone Requester Address City State Zip Code Mower Model Serial Number Date Purchased DealerSalesperson Dealership Name DealershipLocation Mail to AEM Video Services 1502 E Walnut street Seguin TX 78155 Or Fax to 830 372 9529 Or Email to AEMVideo alamo group com ...

Page 9: ...Safety Section 1 1 2009 Alamo Group Inc SAFETY SECTION ...

Page 10: ... Symbol and Signal Word are intended to warn the owner operator of impending hazards and the degree of possible injury faced when operating this equipment Indicates an imminently hazardous situation that if not avoided WILL result in DEATH OR VERY SERIOUS INJURY Indicates an imminently hazardous situation that if not avoided COULD result in DEATH OR SERIOUS INJURY Indicates an imminently hazardous...

Page 11: ...fety Messages found in the Manual or on the Tractor and Implement Learn how to stop the tractor engine suddenly in an emergency Never allow inexperienced or untrained personnel to operate the Tractor and Implement without supervision Make sure the operator has fully read and understood the manuals prior to operation SG 4 The operator and all support personnel should wear hard hats safety shoes saf...

Page 12: ...ould result if the operator is under the influence of drugs or alcohol SG 27 Prolonged operation may cause operator boredom and fatigue affecting safe operation Take scheduled work breaks to help prevent these potentially impaired operating conditions Never operate the Implement and Tractor in a fatigued or bored mental state which impairs proper and safe operation SG 32 Use extreme caution when g...

Page 13: ... other solid objects Such an impact could cause the Implement and Tractor to pivot violently resulting in loss of steering control serious injury or even death Never allow the Implement to contact obstacles S3PT 12 There are obvious and hidden potential hazards in the operation of this Mower REMEMBER This machine is often operated in grass and in heavy weeds The Blades of this Mower can throw obje...

Page 14: ...eaking and make the final cut more uniform SFL 6 Operate this Equipment only with a Tractor equipped with an approved roll over protective system ROPS Always wear seat belts Serious injury or even death could result from falling off the tractor particularly during a turnover when the operator could be pinned under the ROPS SG 7 BEFORE leaving the tractor seat always engage the brake and or set the...

Page 15: ...d use Cardboard to check for evidence of oil leaks If you suspect a leak REMOVE the HOSE and have it tested at a Dealer If oil does penetrate the skin have the injury treated immediately by a physician knowledgeable and skilled in this procedure SG 15 Never run the Tractor engine in a closed building or without adequate ventilation The exhaust fumes can be hazardous to your health SG 23 Do not exc...

Page 16: ...jects to be thrown outward at very high velocities To reduce the possibility of property damage serious injury or even death never allow the cutting blades to contact such obstacles SGM 4 Extreme care should be taken when operating near loose objects such as gravel rocks wire and other debris Inspect the area before mowing Foreign objects should be removed from the site to prevent machine damage a...

Page 17: ... down the Tractor and Mower and clean clippings and collected debris from the mower deck SGM 12 The Mower is designed for certain mowing applications and is rated to cut up to a specific size vegetation see Mower Standard Equipment and Specifications DO NOT use this mower to cut vegetation above the Mower s rated capacity or to cut any type of non vegetative material Only operate this Mower on a p...

Page 18: ...ng distances can be substantially increased by the momentum of the rotating Mower blades driving the Tractor transmission even though the Tractor clutch has been disengaged Install an over running clutch between the Tractor PTO and the Mower driveline to prevent this potentially dangerous situation S3PT 16 When attaching the Implement input driveline to the Tractor PTO it is important that the con...

Page 19: ...p loss of steering control or Tractor tip over Slow down on rough or uneven surfaces to prevent loss of steering control which could result in property damage or possible injury Do not transport unless 3 Point lift lever is fully raised and in the latched transport position Dropping implement in transport can cause serious damage to the tractor and or Implement and possibly cause the operator or o...

Page 20: ...sport the Tractor and Implement at the speeds which allow you to properly control the equipment Be aware of the operating conditions Do not operate the Tractor with weak or faulty brakes or worn tires When operating down a hill or on wet or rain slick roads the braking distance increases use extreme care and reduce your speed When operating in traffic always use the Tractor s flashing warning ligh...

Page 21: ...y Shields Guards and Safety devices including but not limited to the Deflectors Steel Guards Gearbox Shields PTO integral shields and Retractable Door Shields should be used and maintained in good working condition All safety devices should be inspected carefully at least daily for missing or broken components Missing broken or worn items must be replaced at once to reduce the possibility of injur...

Page 22: ...ges Sharp surfaces can inflict severe laceration injuries if proper hand protection is not worn SG 37 Replace bent or broken blades with new blades NEVER ATTEMPT TO STRAIGHTEN WELD OR WELD HARDFACING ON BLADES SINCE THIS WILL LIKELY CRACK OR OTHERWISE DAMAGE THE BLADE WITH SUBSEQUENT FAILURE AND POSSIBLE SERIOUS INJURY FROM THROWN BLADES SGM 10 DO NOT weld or repair rotating mower components Welds...

Page 23: ...M 3 Always disconnect the wire leads from the mower valve solenoid before performing service on the Tractor or Mower Use caution when working on the Tractor or Mower Tractor engine must be stopped before working on Mower or Tractor The Mower Blades could inadvertently be turned on without warning and cause immediate dismemberment injury or death SBM 12 In addition to the design and configuration o...

Page 24: ...te safe operation Damage to the decals may occur while in shipping use or reconditioning Alamo Industrial cares about the safety of its customers operators and bystanders and will replace the safety decals on this product in the field free of charge Some shipping and handling charges may apply Contact your Alamo Industrial dealer to order replacement decals ...

Page 25: ...47 REFLECTR SMV Reflector 16 1458392 4 REFLECTR Red Reflector Decal 17 1458393 4 REFLECTR Yellow Reflector Decal 18 02966305 1 INSTRUC Hyd Oil and Type 19 03200432 3 INSTRUC Genuine Alamo Flail Parts 20 002023 3 INSTRUC Cutting Height Adjustment 21 001412 1 INSTRUC Valve Lever Operating Plate 22 000108 3 INSTRUC Flail Operation 23 000678 2 INSTRUC Grease Fitting Inside 24 001829 2 INSTRUC Wing Lub...

Page 26: ...on 1 18 2009 Alamo Group Inc SAFETY Decal Description Danger Mult Hazard Warning Failing to follow these Safety Messages and Operating Instructions can cause serious bodily injury or even death to operator and others in the area P N 002369 ...

Page 27: ...nds feet or limbs may occur from blades contact Always make sure that all shields are in place at all times P N 002425 DANGER Stay clear when lowering or raising wings P N 00753840 DANGER Guard Missing Do Not Operate If you see this decal Do Not Operate the mower until the shield has been replaced P N 00756004 DANGER Rotating Driveline Keep Away Contact can cause death P N 00756005 ...

Page 28: ...epaired and replaced when damaged so that machine stays in safe condition P N 00756007 WARNING Never use your hand to check for oil leaks Always use paper or cardboard P N 00756059 DANGER Keep Away Rotating Blades P N 00756485 DANGER Make certain that drivelines are correct length and are securely attached P N 00756494 ...

Page 29: ... may be pinched off if get caught between V Belt and Pulley P N 00758194 DANGER Crushing and Pinch Points Moving machiney parts can pinch or crush or fall which may cause injury or death P N 02962765 CAUTION Watch your step P N 03200285 DANGER Transport with Lever in Neutral Position to prevent inadvertent unfolding P N 03200328 ...

Page 30: ... cap Stay clear to prevent being scalded with hot oil which may cause serious injury to eyes face and exposed skin P N 02971123 Slow Moving Vehicle Decal Keep SMV reflector clean and visible DO NOT transport or operate without the SMV P N 03200347 Red Reflector Keep reflectors clean and visible P N 1458392 Amber Reflector Keep reflectors clean and visible P N 1458393 ...

Page 31: ...FETY INFORMATION Attention Service Hydraulic System with Universal Tractor Hydraulic Oil Alamo Group part Number 02966307 02966305 IMPORTANT Use ALAMO Genuine Flail Parts P N 03200432 Cutting Height Adjustment Chart P N 002023 Cylinder Controls for Lift and Tilt 001412 ...

Page 32: ...Instructions to properly lubricate and check mower for potential problems prior to operation P N 000108 Information that Grease Fitting is present and must apply grease P N 000678 INFORMATION 8 Hour Lubrication Chart P N 001829 INFORMATION 8 Hour Lubrication Chart P N 001830 ...

Page 33: ...sing the mower attachment operate tractor at the engine speed which will deliver 540 PTO RPM on Tachometer Over speeding the engine and pump when operating the mower will overheat and rapidly ruin the oil which will decrease the life of the hydraulic components P N 02965093 Operator s Manual with repair parts and warranty was attached to this implement during final inspection P N 00763977 ALAMO NA...

Page 34: ...up Inc SAFETY ALAMO INDUSTRIAL LOGO P N 001651 NAME LOGO Alamo Industrial P N 02960766 INTERSTATER NAME LOGO P N 001660 Read Operator s Manual The operator s manual is located inside this canister If the manual is missing order one from your dealer P N 00776031 ...

Page 35: ...fe operation and servicing of all equipment with which the employee is or will be involved Employer Responsibilities To ensure employee safety during Tractor and Implement operation it is the employer s responsibility to 1 Train the employee in the proper and safe operation of the Tractor and Implement 2 Require that the employee read and fully understand the Tractor and Implement Operator s manua...

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Page 81: ...Introduction Section 2 1 2009 Alamo Group Inc INTRODUCTION SECTION ...

Page 82: ...rouble Shooting Guide helps diagnose difficulties with mower and offers solution to the problems Safety is of primary importance to the owner operator and to the manufacturer The first section of this manual includes a list of Safety Messages that if followed will help protect the operator and bystanders from injury or death Many of the Safety Messages will be repeated throughout the manual The ow...

Page 83: ...ith 10 gauge steel and end plates that are 1 2 thick for the inboard and 5 16 thick steel for the outboard Smart front mount hydraulic pump that drives power from the crankshaft of tractor while twin piston pumps provide the power for the wing mowing units Knife Variety An array of cutting knife options allows you to tailor the finished appearance to meet your needs Cutting Capacity 1 diameter gra...

Page 84: ...lement 2 Fill out the Warranty Card in full Be sure to answer all questions including the Serial Number of the implement Mail within 30 days of delivery date of this implement NOTE Warranties are honored only if completed Owner Registration and Warranty forms are received by Alamo Group within thirty days of delivery of the implement 3 Record the Model and Serial Numbers on the Warranty page at th...

Page 85: ...Assembly Section 3 1 2009 Alamo Group Inc ASSEMBLY SECTION ...

Page 86: ...id when filling the system USE ONLY TRACTOR HYDRAULIC OIL IN THE HYDRAULIC SYSTEM Reference to the left or right side of the Interstater is determined while facing the front of the tractor from the drivers seat Reference to the left or right side of the Interstater is determined while facing the front of the tractor from the drivers seat Assemble the Interstater step by step as illustrated on the ...

Page 87: ...ve foot step from each side of tractor to which a mower will be mounted Front tractor wheels may require a wider adjustment to clear hydraulic tank and tank mounting frame SPECIAL TOOLS Special tools for installing and servicing INTERSTATER kits are illustrated on the below Drawings for these tools are available on request If desired tools may be obtained from Alamo on a made to order basis Prices...

Page 88: ...ar Tractor Installation Drawing for part numbers and quantities ASM FL 0003 2 Attach the right hydraulic tank support to the tractor with 4 bolts provided in your Mount Kit Refer to your particular Tractor Installation Drawing for part numbers and quantities ASM FL 0004 3 To make assembly easier the hard plumbing assembly should be installed on the Mainframe before the Mainframe is installed Use 2...

Page 89: ...er onto hydraulic tank supports Attach the bumper to the tank supports with 4 1 2 x 2 bolts and 4 1 2 locknuts ASM FL 0007 3 Now tighten all hardware for mainframe tank support tank and bumper LIFT CYLINDER FRAME ATTACHMENT Position the right and left lift cylinder supports and loosely install the 6 3 4 x 2 1 4 bolts and 6 3 4 locknuts to each side Pull the supports outward and downward to remove ...

Page 90: ...e raised and lowered For tractors equipped with a cab a collar may need to be installed on the lift cylinder rod for proper alignment of the transport lock Remove the cylinder end and the locking collar Install the extra collar onto the rod and reassemble ASM FL 0011 MOUNTING WING MOWERS Assemble Skid Shoes on Cutter before mounting the head With the cutter housing tipped up attach housing shoes w...

Page 91: ...f the tilt cylinder Use the pin located in the ears on the end of the housing and secure with the cotter pins Reinstall belt guard Attach the air breather Item 1 to the hydraulic tank ASM FL 0015 Insert driveshaft through the pump mount weldment until it slides into the crank shaft pulley coupling When using auxiliary hydraulic pump place the pump drive belt around driveshaft Place splined pulley ...

Page 92: ...olts 2 1 2 flatwashers and 2 1 2 locknuts Wrap belt around pulleys adjust tension and tighten all bolts securely ASM FL 0018 ELECTRICAL WIRING INSTALLATION To prevent any damage to electrical system during wiring procedures temporarily remove the negative lead ground from battery terminal Asm R 0018 Remove ignition switch access panel or ignition switch if panels are not provided in dash Identify ...

Page 93: ... from the safety switch must be routed close to cutter housing sidesheet and lift frame pivot points This will prevent wires from being stretched and broken when cutter housing is raised or lowered to maximum positions NOTE Route wires in such a manner to prevent interference with the operation of tractor or INTERSTATER Ensure that wires DO NOT lay against anything which could wear through insulat...

Page 94: ...ASSEMBLY INTERSTATER 03 09 Assembly Section 3 10 2009 Alamo Group Inc ASSEMBLY ...

Page 95: ...ith 3 1 2 x 1 1 2 bolts and 3 1 2 locknuts ASM FL 0024 Attach valve stand to the valve mount bracket with 2 3 8 x1 1 4 bolts and 2 3 8 locknuts ASM FL 0025 Attach control valve to the valve stand with 2 3 8 x1 bolts 2 3 8 locknuts Attach the top cover and the bottom cover to the valve mount bracket with 8 3 8 x1 bolts 8 3 8 washers and 8 locknuts ASM FL 0026 ...

Page 96: ...fitting and a swivel fitting Hoses with two solid fittings will fit into either a female solid thread or a swivel adapter union When installing either type hose solid fittings must be installed first then install the swivel end of the hose The INTERSTATER hydraulic system incorporates three basic types of hydraulic fittings a Standard pipe NPT or NPTF thread fittings This type requires a small amo...

Page 97: ... p n 001783 Items 3 and 4 from the Hydraulic Pump to the vertical suction tubes on the hydraulic tank ASM FL 0029 Fit hoses and cut to length so that there is no kink after they are installed 3 Attach the left wing pressure hose Item 1 to the first Hydraulic Pump ASM FL 0030 4 Attach the right wing pressure hose Item 2 to the second Hydraulic Pump ASM 0030 5 Slide the Protective Sleeving Item 3 ov...

Page 98: ...ASSEMBLY INTERSTATER 03 09 Assembly Section 3 14 2009 Alamo Group Inc ASSEMBLY 6 Attach the Return Hose Item 1 to Left Wing ASM FL 0032 0033 Slide Protective Sleeving Item 2 over the Return Hose ...

Page 99: ...ulic motor ASM FL 0034 0035 Slide right wing pressure hose Item 1 ASM FL 0036 and 0037 through protective sleeving Item 4 ASM FL 0037 and attach to right wing hydraulic motor Attach right wing return hose to hydraulic adapter Item 3 on right wing Item 2 ASM FL 0036 and slide through the sleeving This sleeving will now have both right wing pressure hose and right wing return hose ASM FL 0037 ...

Page 100: ...the hard plumbing ASM FL 0039 NOTE the nut on the 3 way fitting must be loosened before the return hose can be attached ASM FL 0039 Install the vent plug P N 000696 Item 1 ASM FL 0040 plug into upper port of each lift cylinder NOTE On some model lift cylinder ports must face forward for proper hose clearance Install the 90 deg elbow fittings P N 02045200 Item 2 ASM FL 0040 into the remaining lift ...

Page 101: ...hose Item 1 ASM FL 0041 from auxiliary pump to hydraulic tank Attach the pressure hose Item 1 ASM FL 0042 from the auxiliary pump to the control valve Item 1 ASM FL 0042 Attach the return hose Item 2 ASM FL 0043 from the control valve to the return filter on the hydraulic tank Item 1 ASM FL 0044 ...

Page 102: ... Valve to Tilt Cyl Live End 5 001774 1 Hose Control Valve to Tilt Cyl Dead End 4 001772 1 Hose Control Valve to Lift Cyl Live End 3 001771 1 Hose Control Valve to Lift Cyl Live End 1 001770 1 Hose Control Valve to Tilt Cyl Dead End 2 001770 1 Hose Control Valve to Tilt Cyl Live End Hose used with most non cab tractors See Installation Instructions that were shipped with your unit for proper replac...

Page 103: ... Assembly to expose the female threaded end of the Plunger Rod ASMP FL 0002 Then while holding the Handle to expose the Plunger Rod thread the Threaded Bead ASMP FL 0003 of the Cable into the end of the Plunger Rod and tighten securely Release the Handle allowing the Cable to pull into the Control Stick Assembly Once Cable is attached to Plunger Rod slide the silver Conduit Sleeve ASMP FL 0004 int...

Page 104: ...ugh to allow axle to pivot through its full range While turning wheels through their limits right and left swing them up and down Look for interference between tires and any part of the INTERSTATER If interference occurs shims not furnished must be welded to axle pivot stop or steering arm to limit the movement enough to avoid interference Tractors with an adjustable front axle may require an outw...

Page 105: ...discharged through the air filter on top of the hydraulic tank Start the tractor and run it for 2 minutes and then turn it off Again check the oil level in the sight gauge If the oil level is in the sight gauge the unit is ready to run If no oil is seen add oil to bring the level up to the sight gauge Remove all foreign objects and stand clear of cutter units DO NOT GET NEAR ROTATING KNIVES NOTE O...

Page 106: ...he adjustable stiff link furnished with the tractor After the mower is attached to the tractor s 3 point hitch but before the universal slip joint is installed and with the mover on the ground adjust the top link of the hitch to make the mower gearbox input shaft parallel to the tractor P T O shaft This relationship provides optimum operation of the universal joints in the driveline Driveline that...

Page 107: ...tach overarms to cutterhousing Secure each in 2 places with 5 8 NC x 1 3 4 Hex Head Capscrew 1 and nut 2 Attach A frame arms to front of cutterhousing Secure each plus overarms in place with 5 8 NC x 2 1 2 HHCS and nut 2 3 Attach gearbox mounting frame to overarms and A frame arms ASM FL 0049 a Secure with 5 8 NC x 1 3 4 HHCS and nut 3 Torque to 170 ft lbs b Secure with 3 4 NC x 3 3 4 HHCS A frame...

Page 108: ...its remove only the lower two fasteners b Slide bearing housing HHCS into proper holes in outboard bearing plate c Attach gearbox and mounting bracket to gearbox mounting frame Secure with 5 8 NC x 1 1 4 HHCS upper gearbox feet and 5 8 NC x 1 1 2 HHCS lower gearbox feet and Lockwashers Torque to 170 ft lbs Typ If extension shaft does not line up with Gearbox it may be necessary to shim gearbox mou...

Page 109: ...ly grease shaft Install key and driveshaft pulley Do not secure at this time 4 Align all three pulleys Use spacers and shims provided to achieve alignment then secure idler arm assembly with cotter pin 4 Secure driveshaft pulley 1 with fasteners that were retained during previous step 5 Install drive belt 2 6 Attach spring One end is inserted in idler arm spring arm hole the other end is attached ...

Page 110: ...UNIVERSAL SLIP JOINT PTO SHAFT Refer to instructions supplied with shaft To install the driveline separates slip joint halves then install them onto mower gearbox input shaft and tractor PTO driveline according to illustration on PTO shaft shield Hold halves side by side then raise and lower the mower to determine that there is no interference between halves when in the shortest position and that ...

Page 111: ...Operation Section 4 1 2009 Alamo Group Inc OPERATION SECTION ...

Page 112: ...are not specific to any model Some pictures may show shields removed for picture clarity NEVER operate implement without all shields in place and in good operational condition The operator must be familiar with the mower and tractor and all associated safety practices before operating the mower and tractor Proper operation of the mower as detailed in this manual will help ensure years of safe and ...

Page 113: ...e Greasable Self Aligning Cuttershaft Bearings 53 HP Piston Motor Belt Drive From Motor to Cuttershaft with Automatic Spring Tension 6 Adjustable Rear Roller 1 2 to 6 Cutting Height Available in Fine or Coarse Cut Front and Rear Safety Deflectors Automatic Cut Off Switch Lift Cylinder Capable of 14 Vertical Lift Tilt Cylinder Capable of 45 Degrees Down 90 Degrees up 10 Gauge Unitized Cutter Housin...

Page 114: ...nal Protective Equipment PPE for the job conditions when attaching operating servicing and repairing the equipment PPE is designed to provide operator protection and includes the following safety wear PERSONAL PROTECTIVE EQUIPMENT PPE Protective Eye Glasses Goggles or Face Shield Hard Hat Steel Toe Safety Footwear Gloves Hearing Protection Close Fitting Clothing Respirator or Filter Mask depends o...

Page 115: ...he tractor engine 3 1 ROPS and Seat Belt The tractor must be equipped with a Roll Over Protective Structure ROPS tractor cab or roll bar and seat belt to protect the operator from falling off the tractor especially during a roll over where the driver could be crushed and killed Only operate the tractor with the ROPS in the raised position and seat belt fastened Tractor model not equipped with a RO...

Page 116: ... getting onto the tractor the operator must read and completely understand the implement and tractor operator manuals If any part of either manual is not completely understood consult an authorized dealer for a complete explanation OPS U 0007 Do not mount or dismount the Tractor while the tractor is moving Mount the Tractor only when the Tractor and all moving parts are completely stopped SG 12 4 ...

Page 117: ...e remove the key and wait for all motion to come to a complete stop before exiting the operator s seat NEVER leave the seat until the tractor its engine and mower head movement have come to a complete stop Use hand rails and extra steps when exiting the tractor Be careful of your step and use extra caution when mud ice snow and other matter has accumulated on the steps and handrails Never rush or ...

Page 118: ... neutral The boom operating controls are in the neutral and off position The PTO control lever is disengaged The hydraulic remote control levers are in the neutral position Refer to the tractor owner s manual for tractor starting procedures Only start the tractor while seated and belted in the tractor operator s seat Never bypass the ignition switch by short circuiting the starter solenoid After t...

Page 119: ... the top link hitch pin and insert retaining pin into hitch pin 8 Adjust any lower link check chains guide blocks or sway blocks to prevent the mower from swaying side to side and possible contact with tractor rear tires Always shut the Tractor completely down place the transmission in park and set the parking brake before you or anyone else attempts to connect or disconnect the Implement and Trac...

Page 120: ...ry low cutting heights striking the ground with the blades gives the most damaging shock loads and will cause damage to the mower and drive Blades contacting the ground may cause objects to be thrown out from under the mower deck Always avoid operating the mower at a height which causes the blades to contact the ground OPS U 0010 Never work under the Implement the framework or any lifted component...

Page 121: ...e removed A stuck roller could drop unexpectedly and cause injury 6 Use lifting device to reposition cutter housing to desired cutting height Align bracket holes with cutter housing then reinstall hardware 7 Lower cutter housing to the ground and remove lifting device 8 Set cutting height according to procedures above for remaining two cutter sections Make sure that all three rollers are set at th...

Page 122: ...RIVELINE ATTACHMENT The driveline yoke and tractor PTO shaft must be dirt free and greased for attachment To connect the mower driveline to the tractor PTO output shaft pull the driveline yoke collar back and align the grooves and splines of the yoke with those of the PTO shaft Push the driveline yoke onto the PTO shaft release the locking collar and position the yoke until the locking collar ball...

Page 123: ...ent of 12 must be maintained Bottoming Out Check Procedure Disconnect driveline from the tractor and slide the profiles together until fully compressed Place a mark on the inner shield 1 8 from the end of the outer shield and reattach the driveline to the PTO Shaft With the PTO NOT TURNING slowly drive the tractor with mower attached through the sharpest turn possible and watch shaft movement With...

Page 124: ...lt an authorized dealer to purchase the required driveline length NOTE If the driveline cannot be shortened and still maintain the required profile engagement the operator must be made aware of terrain conditions and avoid situations which pose a potential problem to avoid damaging the driveline OPS F 0002 9 PRE OPERATION INSPECTION AND SERVICE Before each use a pre operation inspection and servic...

Page 125: ...nd washers Serious injury may occur from not maintaining this machine in good working order SG 21 9 1 Tractor Pre Operation Inspection Service Refer to the tractor operator s manual to ensure a complete pre operation inspection and scheduled service is performed according to the manufacturers recommendations The following are some of the items that require daily service and inspection Tire conditi...

Page 126: ...issing or broken components Missing broken or worn items must be replaced at once to reduce the possibility of injury or death from thrown objects entanglement or blade contact SFL 5 Replace bent or broken blades with new blades NEVER ATTEMPT TO STRAIGHTEN WELD OR WELD HARDFACING ON BLADES SINCE THIS WILL LIKELY CRACK OR OTHERWISE DAMAGE THE BLADE WITH SUBSEQUENT FAILURE AND POSSIBLE SERIOUS INJUR...

Page 127: ... not damaged Replace worn broken and missing sections immediately Ensure the rollers are in good condition and rotate freely Ensure the driveline integral shield is in good condition and rotate freely Inspect that all bolts and screws are in position and are properly torqued OPS F 0004 Inspect the condition of the wings and rear section drive belts Ensure the slip clutch rear mower section only is...

Page 128: ...g the tank with oil after initial filling may result in oil being discharged through the air filter on the top of the hydraulic tank Perform scheduled lubrication as specified in the maintenance section OPS F 0006 Inspect cutter knives and knife pins for looseness and excessive wear Make sure the mower is securely blocked up before crawling beneath Replace damaged worn and missing knives as comple...

Page 129: ...ade has Become bent or deformed from it s original shape or Any cracks are visible or Deep gouges in the blade s surface are persent or Gouges or chipped areas in the cutting edge are larger than 1 2 12 7mm or The material on the leading edge has been worn away by more than 1 2 12 7mm Failure to replace abnormally worn blades may lead to catastrophic failure of the blades and ejection of the broke...

Page 130: ...LADE BOLTS on the Blades IMMEDIATELY if either blade bolts has Visible cracks or If the recessed area on blade bolt is worn off or If Blade Bolt has gouges or chipped areas Failure to replace abnormally worn blade bolts may lead to catastrophic failure of the blades and ejection of the broken part which may cause serious bodily injury or death Always replace Blade Bolts with new bolts whenever rep...

Page 131: ...l is in the canister on the mower All safety decals are in place and legible The hitch connection bolts pins are tight There are no cracks in hitch Their mower deck is clear of cut grass and debris The thrown object guard deflectors are in place Their guards deflectors are in good condition The driveline gearbox shields are in good condition The driveline clutch is in good condition not frozen The...

Page 132: ...e SMV Sign is clean and visible The tires are in good condition with proper pressure The wheel lug bolts are tight The tractor brakes are in good condition The steering linkage is in good condition There are no visible oil leaks The hydraulic controls function properly The ROPS or ROBS Cab is in good condition The seatbelt is in place and in good condition The 3 point hitch is in good condition Th...

Page 133: ...ring and brakes are in good condition and operate properly Before transporting the Tractor and Implement determine the proper transport speeds for you and the equipment Make sure you abide by the following rules Test the tractor at a slow speed and increase the speed slowly Apply the Brakes smoothly to determine the stopping characteristics of the Tractor and Implement As you increase the speed of...

Page 134: ... locked together to provide simultaneous rear wheel braking FOR MOST DRIVING AND OPERATING CONDITIONS THE BRAKE PEDALS SHOULD BE LOCKED TOGETHER TO PROVIDE THE MOST EFFECTIVE BRAKING ACTION Always disengage the tractor differential lock when turning When engaged the differential lock will prevent or limit the tractor from turning During normal cutting conditions locking the differential provides n...

Page 135: ... support bar clearance Loosen rod end clamp Shorten stroke on LIFT cylinder to raise lift frame Lengthen stroke on LIFT cylinder to lower lift frame and or Shorten stroke on TILT cylinder to move transport bracket closer to support bar Lengthen stroke on TILT cylinder to move transport bracket away from support bar Once sufficient clearance is obtained tighten rod end clamp The mower s center of g...

Page 136: ...rd enough to slowly lower unit until it touches ground then push both levers forward to FLOAT position NOTE For best mowing results and longer roller life both LIFT and TILT levers should be in FLOAT position while mowing It takes some effort to pull TILT lever from FLOAT position because of detent spring The mower must be operated with the cutter sections fully lowered and the hydraulic control l...

Page 137: ...he control lever in the transport detent position to prevent damage to the mower driveline and tongue when turning Perform turns with the tractor and units at slow speeds to determine how the tractor with an attached blade or rake handles a turn Determine the safe speed to maintain proper control of the tractor when making turns When turning with a towed implement the overall working length of the...

Page 138: ...shing the PTO into the tractor and through the support bearings or downward onto the PTO shaft breaking it off Damage resulting from over collapse of the driveline s inner profile and its outer housing may allow the driveline to come loose from the Tractor which could cause bodily injury to the operator or bystanders and or extensive damage to the Tractor or Implement OPS R 0020 When contronted wi...

Page 139: ...HE TRACTOR AND IMPLEMENT AND ALL CONTROLS BEFORE ATTEMPTING TO OPERATE The operator must read and understand the Safety and Operation Sections of the implement and tractor operator s manuals These manuals must be read and explained to any operator who cannot read Never allow someone to operate the implement and tractor without complete operating instructions Before starting any operation the opera...

Page 140: ...at once Immediately idle the engine speed and disengage the PTO Wait for all mower rotating motion to stop then raise the mower and move the tractor and implement off the object Inspect the area and remove or mark the location of the debris Inspect the condition of the mower and make any needed repairs immediately Make sure the blades are not damaged and the carrier is balanced before resuming ope...

Page 141: ... spread cut material better eliminatestreaking and make the final cut more uniform SFL 6 11 3 Engaging the Power Take Off PTO Before engaging the PTO make certain that the area is clear of bystanders and passersby The implement must be completely lowered and the deck positioned at a safe operating height NEVER engage the PTO with the implement in the raised position Set the tractor engine speed at...

Page 142: ...ing speed depends on terrain condition and grass type density and height of cut Normal ground speed range is from 2 to 5 mph 3 8 kph Use slow mowing speeds when operating on or near steep slopes ditches drop offs overhead obstructions power lines or when debris and foreign objects are to be avoided SGM 07 11 5 Operating the Mower Only operate the mower from the tractor operator s seat with the sea...

Page 143: ...re no persons behind the mower and use extreme care when mowing in reverse Mow only at a slow ground speed where you can safely operate and control the tractor and mower Never mow an area that you have not inspected and removed debris or foreign material SGM 08 Follow these guidelines to reduce the risk of equipment and grass fires while operating servicing and repairing the Mower and Tractor Equi...

Page 144: ...o the ground shut down the engine remove the key and wait for all motion to come to a complete stop before exiting the tractor OPS F 0011 12 DISCONNECTING THE MOWER FROM THE TRACTOR Before disconnecting the mower the PTO must be disengaged and all motion at a complete stop Move the mower to a level storage location and lower both wings to the ground If the mower will be stored with the sections in...

Page 145: ...efully to avoid damaging the driveline or its shield Do not let the driveline fall into mud or dirt which can contaminate the bearing and shorten the life of the driveline OPS F 0013 Never work under the Implement the framework or any lifted component unless the Implement is securely supported or blocked up to prevent sudden or inadvertent falling which could cause serious injury or even death SG ...

Page 146: ...e mower will be ready for use at the start of the next season Store the mower in a clean dry place with the mower housing resting securely on blocks or at ground level Keep the driveline yoke from sitting in water dirt and other contaminants Use spray touch up enamel where neces sary to prevent rust and maintain the appear ance of the mower It is critical that driveline clutches slip when an obsta...

Page 147: ...ating the tractor and implement and the possibility of accidents are not left behind when you finish working in an area Therefore the operator must employ good judgement and safe operation practices when transporting the tractor and implement between locations By using good judgement and following safe transport procedures the possibility of accidents while moving between locations can be substant...

Page 148: ...e tractor and implement on public roadways The tractor must be equipped with all required safety warning features including a SMV emblem and flashing warning lights to alert drivers of the tractor s presence Remember that roadways are primarily designed for automotive drivers and most drivers will not be looking out for you therefore you must look out for them Check your side view mirrors frequent...

Page 149: ...e SMV emblem if faded damaged or no longer reflective OPS U 0020 Make sure that all tractor flashing warning lights headlights and brake tail lights are functioning properly before proceeding onto public roads While newer model tractors have plenty of lighting to provide warning signals and operating lighting most older models are only equipped with operating lights Consult an authorized tractor d...

Page 150: ...s and gross weight of the complete loaded unit Ensure that the load will be in compliance with the legal limits set for the areas that will be traveled through OPS U 0024 Use adequately sized and rated trailers and equipment to transport the tractor and implement Consult an authorized dealer to determine the proper equipment required Using adequately sized chains heavy duty straps cables and or bi...

Page 151: ...extreme care when attaching and removing the securing devices as the extreme tension involved when released has the potential to inflict serious injury While hauling the tractor and implement make occasional stops to check that the tractor and implement have not moved or shifted and that the securing chains have maintained tension If during transport a hard braking sharp turning or swerving action...

Page 152: ... Dealer improperly Gearbox Noisy Rough Gears Run in or change gears Worn Bearing Replace bearing Noise Damaged Belt Shield Straighten or replace Shields Rubbing on pulleys or belt Worn Bearing or Gear Replace Bearing or Gear Gearbox Leaking Damaged oil seal Replace seal Bent shaft Replace oil seal and shaft Shaft rough in oil seal area Replace or repair shaft Oil seal installed wrong Replace seal ...

Page 153: ...ss Grass too wet Wait for grass to dry Grass too long Mow at 3 1 2 and recut lower Travel speed too fast Use a lower tractor gear PTO RPM too low Mow at engine RPM to match 540 PTO RPM Blades Scalping High Places Mowing too low Raise height of cut Rough uneven ground Use a slower speed Lower rollers Turning Tractor too fast Slow down when turning Uneven Cut Travel speed too fast Use a slower speed...

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Page 155: ...Maintenance Section 5 1 2009 Alamo Group Inc MAINTENANCE SECTION ...

Page 156: ...il at the lower 1 8 pipe plug on the gearbox cover LUBRICATE MOWER BEFORE INITIAL USE NOTE Lubricate flail roller bearing until lubricant can be seen coming out between roller and bearing housing 2 Before each day s use follow this procedure a Visually check the unit and make certain all items are properly tightened b Check the pump drive belt tension If necessary tighten the belt as instructed in...

Page 157: ...9 Alamo Group Inc MAINTENANCE A LIFT FRAME POVOT PIN G REAR MOWER IDLER ARM B WING MOWER BELT IDLER ARM H BANJO BEARING C CUTTERSHAFT BEARINGS J BANJO COUPLING D TILT CYLINDER ROD END K DRIVELINE YOKE E LIFT CYLINDER ROD END L DRIIVELINE SLIP F ROLLER BEARING ...

Page 158: ...s 5 Replace Pump Cover CHANGING HYDRAULIC SYSTEM FILTER A large capacity filter is located on top of the hydraulic oil reservoir Mnt FL 0009 The filter will trap particles which are 001 inch or larger The filter needs to be changed after the first 10 hours of operation and every 200 hours or 12 months thereafter 1 Clean the filter cover to prevent dirt from entering tank 2 Loosen the four bolts on...

Page 159: ...ANCE 5 Remove filter Inspect material trapped by the filter It can indicate parts wear in the system Mnt FL 0008 6 Install the new filter 7 Reinstall filter spring and filter cover Replace the one bolt which had previously been removed Tighten all bolts in an even manner Mnt FL 0009 ...

Page 160: ...ff when the wing is raised to approximately 60 degree angle This also prevents mower from being operated with the wing up This feature prevents injury due to inadvertently starting mower with wing raised and should be kept in proper operating condition D SOLENOID OPERATED VALVE AT MOTOR The electric solenoid valve is mounted in the hydraulic motor manifold block The solenoid controls the spool wit...

Page 161: ...stall idler arm spring and belt guard ADJUSTING CUTTING HEIGHT 1 Lower cutter unit to ground and place control valve levers in FLOAT position 2 Place lifting device scissors jack hydraulic jack under center of cutter housing 3 Remove hex nuts washers and carriage bolts from bracket at each end of roller Make certain that roller bracket is free to move once the fasteners are removed A stuck roller ...

Page 162: ... bearing and housing assemblies proceed to step 8 4 Remove grease fitting from the top of bearing housing 5 Remove bearing form housing By Rotating Bearing 90deg sideways and line up with notches in Bearing Housing then pull out 6 Install new bearing into housing Bearing must be installed with grease hole in bearing aligned with grease fitting hole in housing 7 Reinstall grease fitting to housing ...

Page 163: ...rhousing then remove bearing and housing assembly NOTE There are two tapped holes in the housing which can be used to pull bearing and housing assembly out by using special tool No 701627 6 Using a jack to align parts install bearing and housing assembly to cutter unit and make certain that bearing setscrew is located in keyway on cuttershaft Grease bearing and install cap over fitting If only the...

Page 164: ... cap over fitting 6 Reinstall key and pulley Secure with cuttershaft fasteners 7 Remove jack and check shaft rotation Reinstall knives which were removed 8 Reinstall drive belts then secure motor mounting bracket to cutterhousing 9 Reinstall idler arm spring 10 Reinstall belt guard 11 Remove supports lower unit to ground and test unit 12 Reinstall outboard fender if not already installed CUTTERSHA...

Page 165: ...late and a idler pulley arm Consult parts book for these part numbers Remove the cuttershaft and turn 180 deg Remove the gearbox cuttershaft drive pulley and outboard bearing plate using the proper bearing plate mount the plate to opposite side of mower housing Remove the four bolts that mounts the gearbox and rotate gearbox 180 deg to new position Install cuttershaft pulley gearbox output pulley ...

Page 166: ...are tight and that all lock washers are fully compressed 2 Check all hoses and hydraulic connections to be sure that they are tight 3 Inspect all moving parts and make certain that no wires or hoses will be caught or pinched when the tractor is in operation Secure all wires and hoses 4 Thoroughly lubricate the INTERSTATER Refer to SECTION 2 Illustration 4 5 Change the hydraulic filter and fill the...

Page 167: ...short Bad Solenoid Replace Solenoid Coil Insufficient cutting power Drivebelts slipping Readjust Belt tension and check or low Cuttershaft speed Bound Shaft Free the Shaft Relief Valve setting too low Adjust Relief Valve Solenoid Spool will not shift Replace Valve Cartridge completely Worn Pump or Motor Replace or rebuild Hydraulic Oil overheating Low Fluid level Fill to proper level Mower free to...

Page 168: ...by unscrewing the four thumb screws which hold it in place 2 Disconnect the outer Pump Suction Hose Pump Drain Hose and the Pressure Hose NOTE Clean spills at once Cap all hoses immediately to prevent contamination of the hydraulic system 3 Remove the two bolts which attach the outer pump to the inner pump flange 4 Remove Pump Lightly oil new O Ring and place on inner pump flange Install the new P...

Page 169: ...ulic filter on top of the reservoir Oil is returned from cutter unit cooling tubes and filtered before entering the hydraulic reservoir Oil returning from the control circuit also enters the reservoir thru the filter Use Chevron 1000THF or an equivalent Note Your ambient temperature and operating con ditions may require a different viscosity oil Please consult the oil manufacturer for proper speci...

Page 170: ...llowing procedure should be used if the spring is to be removed from the piston block assembly The spring is highly compressed and the snap ring should not be removed without first compressing the spring The following parts will be needed to disassemble the piston block 2 ea 3 8 I D x 1 1 8 O D flat washer 1 ea 3 8 x 3 1 4 N C capscrew 1 ea 3 8 N C nut Place one of the flat washers over the 3 8 x ...

Page 171: ...as 9 Inspect the thrust bearing and thrust washers for wear 10 Inspect the needle bearing in the housing If the needles are free of excessive play and remain in the bearing cage there is no need to replace the bearing REASSEMBLY 1 Clean all parts in a suitable solvent Lubricate all critical moving parts before reassembly If necessary install new needle bearing in housing with numbered end of beari...

Page 172: ...y Use proper viscosity oil Drive Coupling broken Inspect Coupling for sheared Spline Spline or Key System noisy Air in system due to low oil level Fill in reservoir to sight glass Loose Suction Line Tighten Fittings Clogged Suction Filter Replace Filter Element Internal Pump or Motor damage Disassemble inspect and repair Sluggish response to Air in system See Step 1A 1B 1C 2B acceleration Internal...

Page 173: ...iston block The spring is highly compressed and the snap ring should not be removed without compressing the spring The following parts will be needed to disassemble the piston block 2 ea 3 8 I D x 1 1 8 O D flat washer 1 ea 3 8 I D x 3 1 4 N C capscrew 1 ea 3 8 N C nut Place one of the flat washers over the 3 8 x 3 1 4 capscrew and place this through the center of the piston block Place the other ...

Page 174: ...tem oil to lubricate all critical moving parts before assembly 2 Install one snap ring in rear groove of drive shaft Install one thrust washer thrust bearing and second thrust washer on drive shaft Install second snap ring in front groove on drive shaft 3 Replace needle bearing in housing if necessary Install shaft in housing assembly and install washer Oil O D of new shaft seal and press into pos...

Page 175: ...or will not turn Severely scored backplate Disassemble motor completely Inspect all parts clean all parts replace all worn parts and flush hydraulic system Motor free wheels Oil flow and pressure shut off When the hydraulic system is shut off going to motor either by shutting off the engine on a closed loop system or returning the control valve spool to neutral on an open center system the motor w...

Page 176: ... immediate or premature failure 5 Lubricate all parts with clean hydraulic oil and reassemble Cylinder Rod Maintenance It is important to visually inspect the hydraulic cylinder rods daily before use It is highly recommended that while the machine is stored or getting very little use that a protectant is applied to the hydraulic cylinder rods to prevent degradation If the machine receives more fre...

Page 177: ...and directs oil through the valve back to the reservoir When the spool is shifted oil flows to one side of the cylinder while the other side is opened to the return line The cylinder rod then moves in or out and changes the cutter unit s position In the FLOAT position the spool will open both sides of the cylinder to the return line The cylinder rod is then free to move since oil can enter or leav...

Page 178: ...engine and run at low idle 4 Raise the Tilt cylinder and note the pressure when the cylinder bottoms 5 The pressure should be the same on both circuits 1200 psi If the pressure is 1200 psi on one and not on the other the relief valve and the pump are working fine The problem would be somewhere else 6 If pressure is low on both circuits adjust relief valve Remove hex cap loosen lock nut if present ...

Page 179: ... disassembly USING THE NEW IMPROVED DISKS Do not tighten the six Adjusting Nuts and Bolts 1 until assembly is complete D TO ADJUST To adjust Slip Clutch tighten Bolts 1 until the Nut makes contact with Compression Spring 10 1 After all six Bolts have been assembled so that Nuts contact Springs mark the position of the top flat on each Nut Tighten Nuts 1 3 8 turns as follows Do NOT tighten one bolt...

Page 180: ...the springs are compressed solid Minimum spring length is 1 1 8 The slip clutch should be checked periodically and adjusted to compensate for wear The lining plates are 1 8 thick when new Replace after 1 32 wear If the mower has been idle for an extended period of time or in wet weather before operating check to be sure the friction lining plates are not frozen or rusted together Should this freez...

Page 181: ...s will require less oil and with 88 wings will require more oil The Hydraulic tank only holds 15 gallons of oil and you can not add enough oil to the tank the first time to completely fill the system Oil should be changed after the first 200 hours of operation and every 400 hours of 12 months of operation thereafter The following filling instructions must be carefully followed to prevent pump cavi...

Page 182: ...ne the grade of bolts and the proper torque except when specific torque values are assigned in manual text RECOMMENDED TORQUE IN FOOT POUNDS UNLESS OTHERWISE STATED IN THE MANUAL NOTE These values apply to fasteners as received from supplier dry or when lubricated with normal engine oil They do not apply if special graphited or molydisulphide greases or other extreme pressure lubricants are used T...

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Page 184: ...y labor charges exceeding a reasonable amount as determined by Manufacturer and for returning the goods to the Dealer whether or not the claim is approved Purchaser is responsible for the transportation cost for the goods or part s from the Dealer to the designated factory 3 LIMITATION OF LIABILITY 3 01 MANUFACTURER DISCLAIMS ANY EXPRESS EXCEPT AS SET FORTH HEREIN AND IMPLIED WARRANTIES WITH RESPE...

Page 185: ...ee to the protected area provided by the ROPS REQUIRED OF THE OPERATOR 1 Securely fasten seat belt if the tractor has a ROPS 2 Where possible avoid operating the tractor near ditches embankments and holes 3 Reduce speed when turning crossing slopes and on rough slick or muddy surfaces 4 Stay off slopes too steep for safe operation 5 Watch where you are going especially at row ends on roads and aro...

Page 186: ...INTERSTATER SOM 03 09 Printed in USA P N 803213C ...

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